Process and apparatus for manufacturing roofing elements



Feb. 23 1926. 1,574,385

J. H. GILLIS PROCESS AND APPARATUS FOR MANUFACTURING ROOFING ELEMENTS Filed Ngv. 21, 1923 H0 in eiemevzi' or fk ade 2 Sheets-Sheet 1 1/ me zzzcwnwavz J ATTORNEYS Feb 23 9 1926.

J. H. GBLLIS PROCESS AND APPARATUS FOR MANUFACTURiNG ROOFING ELEMENTS '2 Sheets-Sheet Filed Nov. 21, 1925 ATTORNEYS together by suitable binders.

roof. Since the composition Patented Feb. 23, 1926,

T13 EQJIACONDA SALES COMPANY,

.- STATES P JULZ'UES Iii. GELIE, 0F ELIZABETH, JERSEY, .AQSIGITOR, BY MESH E ABSIG' T ff A con'roaarron or natawaaa'.

@RGCEEELAHD APPARATUS FOR MAN'UFACTURING BOOKING application filed November 21, 1923. Serial No. 676,117.

To all whom it may concern:

Be it known that I, JULIUS H. citizen of the United Elizabeth, in the county of Union, State of New Jersey, have invented certain"new and useful. Improvements in Processes and A GILLIs, a States, residing at paratus for Manufacturing Roofin lE e-' merits; and it do hereby declare the lowing to be'a full, clear,-and exact descrlption of the invention, such as will enable others skilled in the art to which it appertains to make and use the same. i

This invention rclatesto an electrolytic process and apparatus particularly adapted for the plating of non-metall1c articles, especially those which are to receive a platin over a portion only of their surfaces. Thls process and apparatus is peculiarly advantageous in the production of composite roofing elements consistingof a baseof various compositions such as the so-called asphalt roofing, and a protective to the surface of the base. Such composite elements may be made conveniently by applying the metallic coating by electrolyt1c processes, and this invention will be hereafter described in connection with the manufacture of such elements by electrodeposh tion, although the principles of the'invention may be put into ractice in the manufacture of articles of er than rooting elcments.

The roofing elements above referred to are a will be used hereafter to designate such base materials, although it is intended to include various other materials such as cork, wood fibre, asbestos products, and the 1ike,-bound These elcments are produced for commercial purposes in a number-of varying'forms such as single or multiple shingles, tiles, strips, boards and rotectivelayer a 'non-corrodible metal such as copper, is applied only to that portion of the base surface which is exposed when the elements'are laid on the base-does not ordinarily have an electrical conducting surf metal layer applied I area in the usual are to be produced in large quantities it is desirable to provide a process and apparatus by which a deposit of uniform thickness and quality: may be cheaply made and such apparatus should be capable of convenient and efficient operation so that the production of g the elements may-be carried on Without intcrruption.

electrolyte;- and. the metal is deposited ovdr the desired K manner. Since the elements In my co-pending application, Ser. No. i

661,972, filed September 10, 1923, l have described a process and apparatus for the production of these electroplated elements. 11 that process the tanks used consist oil a plurality of cells which are formed by suitable partitions in the main tank. These partitions are preferably disposed in an in clined position and an element or placed on the inclined side wall partition on a suitable support and held there during the deposition by means of an anode which is swung to lie parallel with but spaced from the element. Between the anode and the element member and on the surface of this separator there is aconducting sheet or suit-able contacts so that the the metal is deposited on the base maybe withdrawn therefrom.

ln the particular a is a spacer or separator plating current by which base is of each anacea-Essa idtheapplication referred I to, two tanks containing a series of cells are lOCBIBd'SldG bysidewith a conveyor, there of a car running on As the process'is illustrafedin the hi a track, between vthem.

carried on thecar is moved" slowly along" between the tanks and in its movement it engages the inclined anodes successively and swings them freeironr the base the separator members being attached to the anodes so as to move with them. swung clear the operator, the car,

places an As each anode is who is sitting on unplated element in position on removes the plated elementand iii the support. He then swings the anode and separator back to plating position and the deposition begins.

in that apparatus the separator is described as formed of a plate of insillatin material such as wood or insulated meta having contact areas on one face. These areas may be in the form of contacts which are exposed in the face of the separator or else the entire face may be covered with a.

sheet of conducting material. T heseparator has its lower edge provided with cutouts or indentations which serve to define the outline of the deposit. The separator-there illustrated is satisfactor for ordinary p111: .poses' but it has'been ound that in use a slight deposit of the metal will build u at the ed e of the contacts and eventually orm trees which build up in the direction of the anode and may eventuallyserve to short circuit the cell. t therefore becomes necessary periodically to dismantle the anode, re move the'separator from it and clean-off.

the builtup deposit.

In the present invention I have devised an improved form of separator arranged so that it is reversible. This memberhas con.- tzict areas formed on either face and when a deposit has been built u alon the edgein the manner above descri ed t e separator ,is reversed and this deposit is depleted. It

' illustrated that embodiment of the invention which is now preferred and in these drawin lg. 1 is a faceview offa base or element without the plating.

Fig. 2 is a face view of the new form of separator, Fig. 3 is a top view of the separator,

Fig. -is an end view oi the separator,

Fig. 5 is a cross-sectional view on the.

line ti -5 of Fig. 2,

Fig. 6 is a face view of'the Wei ts in place thereon,

Fig. 'l is a top view-of this anode, Fig. 8 is an end view of the anode, Fig. 9 is a cross-sectional view through one compartment of the electrolytic tank, showing a base in place therein,

Fig. 10 is a longitudinal, vertical, crossanode showing sectional view through a'compartment of' the tank, showi g the anode, separator and plating position,

area which has a width slightl longer than .to provide extending tongues 15 shown in tongues 22, these tongues being spaced so as Fig. 11 is a view of the element showin the metal coating deposited thereon, an

Fig. 12 is a view similar to Fig. 10 but. showing amodified formzof assembly.

In these drawings the base blank 13' is of the. form used for a three-unit shingle. This base. is of rectangular t'orm, having a len h e uivalent to three single shingles lei side side, and along that edge of the element w ieh will be exposed when it is 7 laid in place on the roof are cut-outs 14. 'When the elements are laid in courses the overlying course will conceal the ends of.

.the cut-outs in the course next below so that each course will appear to be made up. of single shingles spaced .apart by the width of the cut-outs. The roof made of these elements, therefore, hasthe ordinary appearance of the wooden shingled root.

Inasmuch as it is necessary to provide a 8 protective metal layer only over that portion of the element which will be exposed whenit is laid, the deposit does not cover. the entire face of the element but covers an e0 the-depth of the cut-outs. A so, since the cut-outs of the course above will expose" portions of the element somewhat behind the main body of the layer, it is desirable Fig. 11 which are so located as to underlie the cut-outs of the course next above. With this arrangement it will be seen that all exosed portions of the elements are protected y metal and at the same time this metal is not alpplied to any portion which is con: ceaIe The elements, when laid, therefore, will give the roof the appearance of a metal roof, while only sufficient metal necessary for this purpose is employed.

Referring to Figs. 9. and 10, it will be seen that the electrol tic tank consists of bottom, side and endwalls 16 which may be made of slate or wood, provided with a protective sheathing. Any material which is capable of withstanding the action of the electrolyte may be used for this purpose, although the sheathing should be a inert-conductor of electricity. In Fig. 9 the cell is indicated as havinga wood'enwall 16, provided with asheathing 17. Extending. across thc cell are upstanding partitions 18, also made of sheathed wood or of other similar material.

These partitions are preferably disposed in an inclined-position for a purpose later to be set f0rth,-nnd the taulc wi l have a plurality ofthese partitions so that in reality it consists of a number of compartments each of which ISYH. cell. In each (if-these cells thiu'e,

is annnode support 19 also made ot'finsulat- T25 ing material and havinga transverse groove 20 in which the anode is momma:

'As shown in Fig. 6, the anode consists of a slab of imetal 21 having upstanding enses to lie opposite the areas on which the metal is to be deposited. Disposed between the tongues are weights 23 which may be of lead,

I 26 which 1t which are not to receive iron, or other suitable metal, preferably covered with ail-insulating varnish and also provided with handles 24 by means of which they may be slipped into osition. The weights are formed with e ge flanges 25, i are so disposed thatthe weights may he slipped down with these flanges engaging the tongues 22 thus holding the weights securely in position. If deemed, the end tongues may be rovided with terminals 27, 27 by means of w ich the current maybe led to the anodes. Also at the lower edge the anodes are provided with beveled surfaces :28 so that when theanodes are mounted in the grooves in the supporting membars in the cells they may be readlly swung to and away from t e partitions l8.

The separator member which is to lie between the element and the anode and time keep the. anode properly spaced from the element and also transmit the weight of theanode to the element so as to hold the latter in position on its support, is shown in Fig. Zas consistin of a piece ot wood. 29 or other similar insu sting material. This separator is so formed along the lower edge as to mask those portions of the element the plating and thus the lower ed e is cut away as at 30 so as to permit the epo'sition of the metal on the areas 15. Also on each face of the separa'tor there is a sheet of conducting material 31. This conductio material is one which is substantially instiluble in the electrolyte under ordina conditions, andfor this urpose it is possible to make use oi sheet cad, particular y in the ordinary deposition process in which the electrolyte is copper sulphate, since the lead is comparatively insoluble in sul huric acid. At one end ofeach face of t e separator is a projecting terminal 32 wh ch makes electrical contact with the sheets 31 at 33. It will be seen that these terminals or contacts are mounted symmetrically so that when the separator is reversed the contacts on the faces are always located in the same position. Also the separator has a central projection 34 extending above its upper edge. "While 1 have illustrated the terminals 32 as being in the form of strips of metal, preferably of copper, making contact externally with the metallic faces 31, if desired, the terminals may he in the form of sockets extending into the body of the separator and providing an in lci-nalpontzurt with the metallic face, Also, while I have illustratcd'i'ace plates which cover the entire surface of the. separator, it is also possible to make use of projecting contact members, for instance, of strips which extend slightly from the face of the separator and are located seas The lower edge of the separator which is line of the deposit but its metallic through which the plating limited tothat surface of .is exposed below the edge of the separator.

in the formto contact with the upper edge of the conductin area of theelement. These contacts will, t erefor, be mounted preferably at the lower edge of the separatorfand will extend around the edges'of the cut-out portions 30.

In the present form or the apparatus 1 find it is possible to make use of the weight of the ,anode and the separator to hold the elements in placeon their sup orting surface and I also find it possible to esign the separator in such a way that the upper e go is a gauge by which the elements are properly positioned in the cell. This feature is 1llustrated in Fig, 10, in which it Will be laid inplace against the inner surface of the partition 18 with the separator 29 bearing against it and held there by the weight of the anode 21 carrying the weights 23. It will be seen that the separator. spaces the anode a considerable distance from the surface of the element and also masks that'sur face except where the deposit is to occur.

under the solution therefore serves to define thcoutline of the deposit. In mounting the elements in place the anode and separator will be swung clear of the partition, the element placed against the surface of the partition and then when the anode and separator are swun back the element will be positioned so t at its upper edge 36 lies even With'the upper edge 87 of the separator. The separator, inturn, is placed with its edge even with thev up or ends of the tongues of the anode and t iis relation of the parts is such that that portion of the'elemen't which is exposed is the ortionover which the deposit is to be ma e. The separator, therefore, not only serves to define the .outweight plus the weight of the anode acts to hold the elcment firmly in place during the plating operation. This masking effect of the separator is also brought about by reason of the fact that, as has previously been described, the element is given a conducting coating preferably of graphite and the separator has a contact surface. The terminal current is re moved l'rom the cell is in contact with this metallic surface and since the metal is a bet tcr conductor than the graphite current does not tend to llow above the line of contact of the separator with the graphite. Consequently, the deposit is closely the element which The plating current may he introduced into the cell either directly through the anill) the plat ing ode or else throughone of the terminals 32- I If the latter method is employed the current will flow into the terminal 32, thence into the plating 31 on the face of the separator,

lilf) clear of the inclined 1partition and then place an element against t 1e face of the partitlon,

centering it properlyas the separator and anode are moved back against t, 01'' 1t 1s also possible to move the anode and separator clear of the paitition by means of the car as.

scribed in my co-pending application reviously referred to, this car having a hoo by 7 means of which theanode s and separators are moved as the car asses the cells. This method of inserting e ements in the cells is repeated until each compartment in the tank has an element in place. Thereafter when' the electrodeposition has been'earrie'd oiilfor.

a length of time sufficient to produce apla'ting of the desired quality and thickness the anodes and separators 'will he moved clear from the elements, the plated elements withdrawn from the cells and unplatedones inserted. I have found that the density of the electrolyte ordinarily used is such that when the separator is made of Wood with its contactarea formed of'a thin sheet of lead this separator will float in the electrolyte and consequently it is not necessary to provide the separator "with clips or some other means by which it may be secured to the anode.

I have found that when the opera-tionof electrodepositin the metal on the elements,

in the manners. ove describEd, is carried on for a considerable length of time a deposit, of the metal will take place at the edges 38 of that contact face of the separator which lies against the element. This deposit does not interfere with the deposition on the aleinents, but as it builds up gradually it tends to extendacross the lower face of the separator and, if permitted to build up indefi nitcly, would eventually reach the anode and thus short circuit the cell. Therefore, it is necessary with the single face separator shown in my previous application, to discontinue the operation of the cells after a certain length of time, to remove the separators and clean off this deposited metal. This mtereferos, to some extent, with the operation of the apparatus and with the present form of separator the difficulties incidental to the formation of this deposit are easily taken care of. When the deposit has been forming on the edge of the separator for a certain len th of time the separator is simply reverse ,this operation being carried on when an element is removed and a new one put in lacein the cell. With this reversal an unp ated face of the separator now lies against the element and that surface on which the deposit is formed lies against the anode. Depending on which form of terminals have been used, it may be necessary in reversin the separator also to reverse the termina s,' but once the cell is in action again the'surface containin the de osit will make contact with the ano e and t e deposit will commence to go into solution. I have found.

it satisfactory to reverse the separator once every eight to twenty-four hours, depending onth'e rate of deposition, which will in turn depend on the current density and various other conditions relating to the electrolysis.

1 have also found that whenthis reversal is vmade the accumulated deposit at once heginsto dissolve and oes into solution under the conditions descri ed in from one third to one half the time that-is required to build it up to a condition which is troublesome. This process of solutioniof the accumulatedmetal may betermed a plating off process, and a the metal plated on'the surfaceof the separator appears to go into solution rapidly and when once the lead'is exposed no further solution takes place, since this metal is comparatively insoluble in the electrolyte employed. This simple reversal of the separator, therefore, automatically cleans from it the accumulatedde osit and itis not necessary to interrupt t e operation of the cell to perform the cleaning, as was previously the case. l i i In the form of ap aratus just described the element is laced against: the face of the partition an the separator laid against it and the separator-and the element held in lace, inturn, by the'weight of the element. Iowever, it is possible to make use of these parts in a somewhat diflerent manner and the modified assembly-is illustrated in Fig. 12. In that figurethe anode 2l used is in the form illustrated in Fi 6, but is not given the beveled lower e ge, nor are the weights 23 mounted u on it. This anod is not moved durin t e operation of the cell, but lies at all times against the partition 18. The separator 29- is then placed with its edge 39 even with the upper edge 40 of'the anode and then the element 35 is laid against the opposite face of the sepalid is plated ed.

always remaining in the p'osition shownsi. The separator, however, performs the, same I operation. may continue without interrup-v tion for an indefinite period. The anodes go into solution after a considerable length of time and must be replaced, but this replacement is only necessary at long intervals and may be quickly performed so that only one cell is out of commission at a time.

Preferably, the operation of the apparatus will be carried on so that thexanodes rerhuire replacement successive] instead of a at once, and in this way t is substitution of a new anode for one 'which has gone almost completelyinto solution will not interfere with the continuous operation. Also, it will be seen that by making use of a reversible separator the cleaning of the accumulated metal which might have a detrimental efiect, is automatically performed and there is no likelihood of any short circuiting of the cell.

While the principles of the invention have been described as at intov practice in the manufacture of roo g elements, it will be clear that the process and apparatus above described are capable of use for various other purposes. The ap aratus illustrated'is in a form which is su1table for the production of three-unit shingles but with slight modifications it may be used for the plating of various other articles. In such other embodiments the shape of the anode and of the separator will depend on the shape of the element and the outline of the area which is to receive the plating, and such other-changes in the details of construction will be made as are necessitated by the peculiar circumstances of each case;

Also, the use of this reversible separator has been described in connection with what may be termed a stationary anode but in some instances it may bedesirable to make use of this separator in a cell in which the anodes and elements are moved along through the cell by means of a conveyor.

*With such an arrangement aseparator of a construction similar to that previously de: scribed might be em loved and the reversihle separator would oiferthe various advantages which have been pointed out. In either case the use of this reversible se arator not only eliminates the cost and do a y incidental to the cleaning operation but it also cuts down the cost 0 installation since with the ordinary separator having but'one contact face it is necessary to provide two complete sets of separators for each set of cells so that one set may be cleaned while till the other is in use This cleaning operation i is not only'expensive but in many instances would result in damage to the contacts and with the se arator designed so" that it may be cleaned y the action of the electrolyte the cost of the installation is lowered and the life of the separator is indefinite. I claim: A

1. In an electrolytic cell; thecombination of an anode, acathode an a reversible separator adgptedto lie between the anode and material on its opposite faces, ada ted to lie between the anode. and catho s with these areas in contact therewith. v

3. In an electrolytic cell, the combination of an anode, a support for the article to be plated, and a separator adapted to lie between an article on the support and the anode and having contact areas of con ductive material on its opposite 'iaccs, ada ted to contact with the article and the an e.

4. In an electrolytic cell, the combination of an anode,- a support for the article to be plated, and a so arator adapted to lie between the anode an an article on the support, and having contact areas on its opposite faces adapted to make contact with the anode and the article, this separator being formed to mask the article and define the shape of the deposit.

5. In an electrolytic cell, the combination of an anode, a support for the article to be plated, and a reversible separator adapted to 1ie-between the anode and an article on the sup ort, this separator having contact areas 0? conductive material for making contact with the anode and the articlc and,

terminals connected witheach area. 6. In an electrolytic cell, the combination of an anode, a support for the article to be plated, and a separator of insulating material'adapted to lie between the anode and the article with portions of its sunfaces in contact therewith and having contact areas of conducting ,material disposed on these g 8, 1. an electrolytic cell containing an.

electrolyte, the combination of an anode, a support for the article to be plated, and a separator adapted' to lie between the anode and the article and having contact areas to make contact therewith,,these contact areas being formed of a metal substantially insoluble in the electrolyte.

, 9. In an electrolytic cell, the combination of an anode, a support for the article to be plated and a separator adapted to lie between the anode and the article and having contact areas to make contacttherewithJhis siparator being formed to define the shape 0 the deposit and having its up or edge serving as a gauge for positioning tlie article on the support.

10. In an electrolytic cell the combination of an inclined support for an article to be plated, a separator adapted to lie against the article and hold it against movement, this separator having a contact area on one face for making contact with the article and a second contact area on its op osite face, and also having one edge formed to define the shape of the deposit and another edge serving as a gauge for positioning the article on the support, and an anode adapted to lie against the second contact area on the separator. d

11. In an electrolytic cell the combination of an inclined support for the article tobe plated, a separator having contact areas on either face adapted to lie with one face in contact with the article, a terminal connected with each contact face, and ,an anode adapted to lie in contact with the second face and to hold the: separator against the article. 1

12. A separator of insulating materialfor use in an electrolytic cell and having conducting areas, one of which contacts with the anode, the other with the cathode, and terminals connected with these conducting areas, this separator being reversible to permit' of the plating oil of material accumulating on the conducting area in contact with the cathode.

13. A se 'arator for use in an electrolytic cell comprising a body formed of insulating material having a shape corresponding to that surface of the cathode upon which no deposit is to take lace, contacts disposed on either face of t e body, and terminals connected with the contacts whereby the plating current may be introduced into the cell through one contact and removed through the other.

14. A separator for use in an electrolytic cell, which compromises a body of insulating material having its opposite faces covered with conductive material and a terminal connected to each face, one of these terminals being disposed at one end of the body and the other at the other end of the position of the separator to plate 0 15. A separator for use in an electrolytic cell containing a solution of a salt of copper, which comprises a wooden body having a shape corresponding to that surface of the cathode which is not to be plated, lead sheets mounted on opposite faces of the body and terminals mounted in the body and electrically connected with the leadsheets.

16. A separator for use in an electrolytic cell which comprises a body ofins'ulating material having conducting members located on either face, a terminal at each end of the body connected with one of the contact members, and a projection disposed central ly on the upper ed 0 of the be y.

17. In a metho of electrodeposition, the

18. In a method of (ilectrodeposition, the

steps of sup orting an insulating separator having con ucting contact areas on either face in a .cell, maintaining the anode and cathode in contact with these areas, lead ing plating current into the cell through the area in contact with the anode and out of the cell through the area in contact with the cathode, and periodically reversin r tihe t e metal deposited on. the area of the separator in contact with the cathode.

, 19. In a method of electrodeposition, the steps of supporting, an insulating separator having conducting contact areas on either face in a cell, maintaining the anode and cathode in contact with these areas, leasing plating current into the cell through the anode, and out of the cell through the area in contact with the cathode, and periodically reversing the position of the separator and the electrical connections, whereby the area previously in contact with the cathode and serving as the negative terminal of the cell is placed in contact with the anode.

20. In a method of elcctrodeposition including the use of an insulating separator having areas of conducting material adapted to lie in contact with the anode and cathode with the plating current passing out of the cellthrough the area on the cathode side, the step of periodically reversing thc'position of the separator to plate off the metal deposited on the area on the cathode side of the separator.

21 1. a method of electrodeposltion in eluding the use of an insulating separator position of the separatorand cha'n 'ng the having ereasof conducting material adaptelectrical connections to plate ofi t e metal ed to lie in eontact with the, anode and depositedon the area previously in contact 10 ratitude and having terminals connected to with the cathode. than areas withthe terminal on the cathode In testimonywhereof I- afiix my signaeitie serving as thenegative terminal of the "ture.

cell, the'swpa of periodically reversingthe JULIUS H. GILLIS. 

